Buell X1 2002 Service Manual page 201

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Cam Bushing Reaming (Crankcase)
1. Separate two halves of crankcase, if not already accom-
plished. Place right crankcase half on flat surface with
gearcase side upward. Bushing to be reamed must be
oriented as shown in Figure 3-67.
2. See Figure 3-69. Position CAMSHAFT BUSHING
REAMER PILOT (Part No. HD-38871) onto gearcase
side of crankcase half; upper right and lower left indexing
holes in pilot must be placed over dowels in crankcase
half. Insert two bolts (supplied with pilot) through two
remaining holes in pilot, and into threaded holes of
crankcase half. Tighten bolts securely.
3. Insert the 11/16 in. diameter reamer through pilot hole
and into bushing while turning reamer clockwise. Con-
tinue turning reamer clockwise through bushing until
smooth shank of reamer passes through hole in pilot.
4. Detach reamer from handle. Pull reamer out opposite
side of crankcase half.
5. Thoroughly clean right crankcase half, removing all
metal chips/shavings. Blow out all oil passages using
compressed air.
Cam Bushing Reaming (Gearcase Cover)
NOTE
For all cam bushings except rear intake, see steps 1 through
6. For rear intake cam bushing, see steps 7 through 12.
Newly installed cam gear bushings in the gearcase cover
must be line reamed, using the right crankcase half as a pilot
for the reamer, to establish correct clearance and to ensure
perfect alignment. If crankcase halves are not separated on
your motorcycle, use a spare right crankcase half to perform
the following line reaming procedures.
1. See Figure 3-62. Bushings (7, 8 and 14) to be reamed
must be installed in gearcase cover (17) as described in
CAM BUSHING INSTALLATION (TO GEARCASE
COVER). Attach gearcase cover to right crankcase half
(10), which has been disassembled from left crankcase
half, securing with a minimum of three mounting screws.
2. Insert a standard 11/16 in. diameter reamer through the
previously reamed cam gear bushing (13) in right crank-
case half, which is in line with one of the bushings to be
reamed in gearcase cover.
3. Turn reamer clockwise through bushing in cover until
reamer bottoms. Then give reamer one complete clock-
wise turn to size the bushing. Continue turning reamer
clockwise while extracting reamer from bushing.
4. Repeat Steps 2 and 3 for remaining two cam gear bush-
ings (except rear intake bushing) in gearcase cover, if
required.
5. Separate gearcase cover from right crankcase half.
Inspect bushings for proper cam gear shaft fit. Repeat
line reaming operation if necessary.
6. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
2002 Buell X1: Engine
3534a
Camshaft Bushing Reamer
Pilot (Part No. HD-38871)
Figure 3-69. Reaming Cam Gear Bushing in Right
Crankcase Half
NOTE
A newly installed rear intake cam gear bushing in the gear-
case cover must be line reamed, using the right crankcase
half as a pilot for the reamer, to establish correct clearance
and to ensure perfect alignment. If crankcase halves are not
separated on your motorcycle, use a spare right crankcase
half to perform the following line reaming procedures.
7. See Figure 3-62. Rear intake cam gear bushing (15)
must be installed in gearcase cover (17) as described in
CAM BUSHING INSTALLATION (TO GEARCASE
COVER).
8. Identify the previously reamed rear intake cam gear
bushing (13) in right crankcase half (10), which has been
disassembled from left crankcase half. Insert the shank
end of REAR INTAKE CAMSHAFT BUSHING REAMER
(Part No. HD-94803-67) through gearcase side of this
bushing.
9. With reamer inserted into bushing in right crankcase half,
attach gearcase cover to right crankcase half, securing
with a minimum of three mounting screws.
10. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
11. Separate gearcase cover from right crankcase half.
Inspect bushing for proper cam gear shaft fit. Repeat line
reaming operation if necessary.
12. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
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